Warp Yarn of Woven Textiles

ABSTRACT

A woven textile is provided that includes a plurality of at least about 300-denier warp yarns and a plurality of weft warns woven together. The plurality of at least about 300-denier warp yarns each include at least two fibers having a resin filament infused with minerals. The woven textile may have thermoreactive properties and may be used in furniture, clothing, and houseware. The woven textile may be manufactured by providing at least two fibers having a resin filament infused with minerals; texturizing the at least two fibers having a resin filament infused with minerals to create a warp yarn of at least about 300-denier; providing a plurality of at least about 300-denier warp yarns and a plurality of weft yarns; and weaving the plurality of at least about 300-denier warp yarns and the plurality of weft yarns.

TECHNICAL FIELD

This disclosure generally relates to textiles, and more particularly relates to woven textiles suitable for furniture, clothing, and houseware, and methods for manufacturing the same.

BACKGROUND

There are various methods of textile production including, knitting and weaving resulting in unwoven and woven textiles.

It is known in the art to knit unwoven textiles using stitches, or loops of yarn that intermesh. With each row of loops, a new loop is pulled through one or more loops from the previous row, creating a meandering path that forms symmetric loops. The resulting textile can be stretched depending on the type of yarn, needle size, and stitch type used. The stretched knitted textile may be more elastic than textiles produced from other methods, for example through weaving.

It is known in the art to weave textiles by interlacing warp yarns and weft yarns at a right angle. The warp yarns run longitudinally, while the weft yarns run across the warp yarns. Textiles can be woven weft-oriented where the weft direction is stronger than the warp direction, or warp-oriented where the warp direction is stronger than the weft direction.

It is known in the art to use fibers having a resin filament infused with minerals in filament yarn and spun yarn. More specifically, Hologenix LLC of Santa Monica, Calif., produces a fiber having a resin filament infused with minerals under the name Celliant®. The contents of Celliant® fiber are described in U.S. Pat. No. 7,074,499 and WO2003083189, which are incorporated by reference herewith. Celliant® fibers are available in polyester and nylon, for both filament yarn and spun yarn. Celliant® polyester filament yarn is manufactured in 50 D(“denier”)/36f DTY(“drawn textured filament”), 75 D/72f DTY, and 150 D/144f DTY. Celliant® 6.6 nylon filament yarn is manufactured in 70/68 DTY. Celliant® spun yarn is available in 100% Celliant®, 50% Celliant®/50% polyester blend, and custom blends.

The mineral-infused yarns in the prior art have been used in articles of clothing to obtain medical benefits. However, the mineral-infused yarns in the prior art cannot be used in performance upholstery woven products in the warp direction as such yarn is too brittle and has too much stretch. Therefore there is a need for a woven upholstery product that provides medical benefits and methods of manufacturing the same.

SUMMARY

According to an aspect of the present invention, a woven textile is provided that includes a plurality of at least about 300-denier warp yarns and a plurality of weft yarns woven together. The plurality of at least about 300-denier warp yarns each include at least two fibers having a resin filament infused with minerals. The at least two fibers having a resin filament infused with minerals are texturized to create the at least about 300-denier warp yarn.

According to an aspect of the present invention, a method for manufacturing a woven textile is provided that includes the steps of, but is not limited to: providing at least two fibers having a resin filament infused with minerals; texturizing the at least two fibers having a resin filament infused with minerals to create a warp yarn of at least about 300-denier; providing a plurality of at least about 300-denier warp yarns and a plurality of weft yarns; weaving the plurality of at least about 300-denier warp yarns and the plurality of weft yarns.

In addition to, or as an alternative to, one or more of the features described above, further aspects of the present invention can include one or more of the following features, individually or in combination:

-   -   the at least two fibers having a resin filament infused with         minerals include at least one of aluminum oxide, silicon         dioxide, titanium dioxide, and combinations thereof;     -   the at least two fibers having a resin filament infused with         minerals have tack;     -   the woven textile is dyed;     -   the plurality of at least about 300-denier warp yarns each         include set yarn with heavy intermingle added;     -   the heavy intermingle strengthens the plurality of at least         about 300-denier warp yarns;     -   the woven textile is a smooth matte finish;     -   the woven textile is a texturized finish;     -   the woven textile is provided for at least one of furniture,         clothing, and housewares; and     -   the woven textile has thermoreactive properties.

These and other aspects of the present invention will become apparent in light of the drawings and detailed description provided below.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a table listing the mineral-infused yarn available in the prior art.

FIG. 2 illustrates a plan view of a woven textile according to the present disclosure.

DETAILED DESCRIPTION

Referring now to the drawings, FIG. 1 describes the different mineral-infused yarns available in the prior art. As shown in FIG. 1, the mineral-infused filament yarn in the prior art is not manufactured in 300-denier or anywhere near the strength of 300-denier yarn. The mineral-infused filament yarns in the prior art are not manufactured as warp yarn.

The present disclosure describes a woven textile 10 (see FIG. 2) which includes a plurality of at least about 300-denier warp yarns 14 and a plurality of weft yarns 12 that are woven together. The plurality of at least about 300-denier warp yarns 14 run in direction 22 and the plurality of the weft yarns 12 are woven through warp yarns 14 in direction 20. The plurality of at least about 300-denier warp yarns 14 may each include two fibers having a resin filament infused with minerals. The minerals may include any of aluminum oxide, silicon dioxide, and titanium dioxide, or a combination thereof.

The two fibers having a resin filament infused with minerals may be texturized to create each at least about 300-denier warp yarn 14. In one example, each of the two fibers having a resin filament infused with minerals is 150-denier. The fibers having a resin filament infused with minerals may have tack to enable the fibers having a resin filament infused with minerals to form the at least about 300-denier warp yarn 14. In one example, the plurality of at least about 300-denier warp yarns 14 may be made of two Celliant® 150 D/72f DTY fibers texturized together and SET yarn with heavy intermingle added. The resulting at least about 300-denier warp yarn 14 may be a 300 D/144f DTY yarn SET with heavy intermingle added.

The heavy intermingle may add physical integrity and durability to each of the at least about 300-denier warp yarns 14 so that the plurality of at least about 300-denier warp yarns 14 can be used as warp yarn and woven without excessive breaking or fraying. The heavy intermingle may be a series of knots or interlacing points throughout the length of each of the at least about 300-denier warp yarns 14. The heavy intermingle may be achieved through an intermingling process. In one example, intermingling may be a heating process. In another example, intermingling may be a process of passing each of the at least about 300-denier warp yarns 14 through an intermingling jet where air flow at a high pressure opens each of the at least about 300-denier warp yarns 14, splicing and intertwining the fibers contained therewith. The at least about 300-denier warp yarn 14 may be a filament polyester and the fill may be a natural or synthetic material to create an array of woven textiles 10.

The plurality of at least about 300-denier warp yarn 14 may be less brittle and have less stretch than other known textiles which may allow for the plurality of at least about 300-denier warp yarns 14 to be used in furniture, clothing, houseware, and other woven performance upholstery products. In one example, the woven textile 10 is a decorative performance textile. The plurality of at least about 300-denier warp yarns 14 may be dyed or stained to be used in woven textiles 10 in a wide array of colors. In one example, the plurality of at least about 300-denier warp yarns 14 may provide for a woven textile 10 with a texturized finish. The woven textile 10 may include patterns. In another example, the plurality of at least about 300-denier warp yarns 14 may provide for a woven textile 10 with a smooth, matte finish. The woven textile 10 may be treated with light acrylic backing and a stain resistance.

According to one example, a method of manufacturing a woven textile 10 may include, but is not limited to, providing at least two fibers having a resin filament infused with minerals; texturizing the at least two fibers having a resin filament infused with minerals to create an at least about 300-denier warp yarn 14; providing a plurality of at least about 300-denier warp yarns 14 and a plurality of weft yarns 12; weaving the plurality of at least about 300-denier warp yarns 14 and the plurality of weft yarns 12. The plurality of at least about 300-denier warp yarns 14 may be held stationary in tension lengthwise while the plurality of weft yarns 12 are drawn through and inserted over and under the plurality of at least about 300-denier warp yarns 14.

The woven textile 10 may have thermoreactive properties derived from the minerals infused in the fibers of the at least about 300-denier warp yarns 14. Examples of the thermoactive properties may include: maintaining a particular temperature, preventing heat transfer from the body to the external environment, providing heat to parts of the body, evading detection by infrared sensors, and changing the wavelength of light reflected through woven textile 10. The plurality of at least about 300-denier warp yarns 14 may also provide for medicinal benefits to the user including, wound healing and increased cell proliferation.

The woven textile 10 offers several advantages over known textiles. In using woven textile 10, a user may receive the health benefits associated with the minerals in the at least about 300-denier warp yarns 14 without sacrificing the durability of woven textile 10. The plurality of at least about 300-denier warp yarns 14 are weavable, viable, and may be more affordable than other mineral-infused yarns and resulting textiles on the market. The plurality of at least about 300-denier warp yarns 14 may also be bleach cleanable allowing for longer-term use.

While several examples have been disclosed, it will be apparent to those of ordinary skill in the art that aspects of the present invention include many more examples and implementations. Accordingly, aspects of the present invention are not to be restricted except in light of the attached claims and their equivalents. It will also be apparent to those of ordinary skill in the art that variations and modifications can be made without departing from the true scope of the present disclosure. For example, in some instances, one or more features disclosed in connection with one example can be used alone or in combination with one or more features of one or more other examples. 

What is claimed is:
 1. A woven textile comprising: a plurality of at least about 300-denier warp yarns; and a plurality of weft yarns woven with the plurality of at least about 300-denier warp yarns; and the plurality of at least about 300-denier warp yarns each including at least two fibers having a resin filament infused with minerals.
 2. The woven textile of claim 1, wherein the at least two fibers having a resin filament infused with minerals include at least one of aluminum oxide, silicon dioxide, titanium dioxide, and combinations thereof.
 3. The woven textile of claim 1, wherein the weft yarns are at least about 300-denier and each include at least two fibers having a resin filament infused with minerals.
 4. The woven textile of claim 1, wherein the woven textile is a woven mesh.
 5. The woven textile of claim 1, wherein warp yarns are high energy dyed.
 6. The woven textile of claim 1, wherein the woven textile is dyed.
 7. The woven textile of claim 1, wherein the woven textile has dye printed thereon.
 8. The woven textile of claim 1, wherein the woven textile is treated with a stain resistance treatment.
 9. The woven textile of claim 1, wherein the woven textile has a light acrylic backing.
 10. The woven textile of claim 1, wherein the plurality of at least about 300-denier warp yarns each include set yarn with heavy intermingle.
 11. The woven textile of claim 10, wherein the heavy intermingle is configured such that it strengthens the plurality of at least about 300-denier warp yarns.
 12. The woven textile of claim 10, wherein the heavy intermingle provides for interlacing points throughout a length of each of the plurality of at least about 300-denier warp yarns.
 13. The woven textile of claim 10, wherein the heavy intermingle provides for interlacing points in the form of knots throughout a length of each of the plurality of at least about 300-denier warp yarns.
 14. The woven textile of claim 1, wherein the woven textile has a smooth matte finish.
 15. The woven textile of claim 1, wherein the woven textile has a texturized finish.
 16. The woven textile of claim 1, wherein the woven textile has thermoreactive properties through infusion of the warp or weft yarns with minerals.
 17. The woven textile of claim 1, wherein the warp yarns and the weft yarns are bleach cleanable.
 18. The woven textile of claim 1, wherein the woven textile is a topical upholstery.
 19. The woven textile of claim 1, wherein the woven textile is a barrier.
 20. A method of manufacturing a woven textile, comprising: providing at least two fibers each having a resin filament infused with minerals; texturizing the at least two fibers having a resin filament infused with minerals to create a warp yarn of at least about 300-denier; providing a plurality of at least about 300-denier warp yarns and a plurality of weft yarns; weaving the plurality of at least about 300-denier warp yarns and the plurality of weft yarns.
 21. The method of claim 20, further comprising intermingling each of the plurality of at least about 300-denier warp yarns.
 22. An upholstery article, at least a portion of which including: a fabric, the fabric including: at least about 300-denier yarn having at least two fibers having a resin filament infused with minerals. 